Senior Special Process Engineer

Senior Aerospace Thermal Engineering, located in Royston, UK, is a leading specialist in the manufacture of high-temperature aerospace components, thermal insulation heat shields, and complex fabricated assemblies. As part of Senior plc, the company supplies major global aero-engine and airframe OEMs, with a strong focus on forming hard-to-shape metals such as Titanium and Inconel.

SATE’s capabilities include advanced hot and cold forming processes-particularly double- and triple-action hot draw forming using six dedicated presses. The business works extensively with high-performance materials including Titanium alloys (Ti 6AL-4V, TA10, TA21), Inconel grades (625, 718), Nimonics, and Jethete to deliver reliable solutions for demanding, high-temperature aerospace applications.

Job Title: Senior Special Process Engineer

Reporting to: Head of Quality & Continuous Improvement

Direct Reports: Special Process Engineer

Purpose of Role:

The Senior Special Process Engineer is the technical owner, strategic leader and primary custodian of NADCAP compliance for all special processes at Senior Aerospace Thermal Engineering (SATE). This role holds accountability for the governance of Chemical Processing, Heat Treatment, Welding, NDT, and Non-Conventional Machining, ensuring the business continuously meets and exceeds the zero-defect standards while actively supporting the broader AS9100 Quality Management System.

Operating as a senior member of the quality team, this role delivers hands-on oversight for the entire process lifecycle - from equipment and process qualification to achieving customer accreditations. Balancing engineering expertise with commercial acumen, this role will lead and develop the special process engineering team, drive operational excellence, ensure document control, support capital improvements, and partner with the Head of Quality & Continuous Improvement to safeguard product integrity and regulatory compliance.

Key Responsibilities:

· Nadcap & Customer Approvals: Hold full accountability for maintaining all Nadcap and customer special process accreditations, including audit management, non-conformance closure, deviation/concession compilation and procedure alignment.

· Technical Process Ownership: Act as the definitive internal subject matter expert and focal point for all special processes, including managing relationships with external stakeholders (e.g., suppliers and customer technical experts).

· Team Leadership: Lead, mentor, and develop special process engineers, overseeing their daily activities and performance.

· Documentation & Change Control: Create, review, and approve all internal procedures, data sheets, and 'return to service' authorisations for special process equipment.

· Quality & Problem Solving: Support the Head of Quality & Continuous Improvement on critical customer escapes (NoEs) and lead root-cause investigations into high-cost special process non-conformances.

· Material Review Board (MRB): Act as the core technical advisor to the MRB for all special process-related topics and material dispositions.

· Internal Audits & Compliance: Execute internal special process audit plans, manage NCR dispositions, and oversee REACH compliance for internal and subcontracted processes.

· NPI & Continuous Improvement: Serve as the Special Process lead for New Product Introduction (NPI) projects and drive continuous improvement initiatives for process efficiency and quality.

· REACH Management: Act as the technical lead for REACH compliance across all special processes, managing risk for internal and subcontracted operations, and approving process modifications where restricted substances or safety concerns are identified.

· Strategic & CAPEX Input: Contribute to strategic planning and propose Capex-backed improvements with supporting financial justifications.

· Deputising: Deputise for the Head of Quality & Continuous Improvement as required.

Company Statement: This job description is not intended to establish a total definition of a job but to outline duties. This job description will be amended at the discretion of management.

Key Requirements:

· Degree, HNC, or HND in Metallurgy, Materials Science, Chemical Processing, or a related Engineering discipline.

· Solid understanding of aerospace metallurgy and materials, specifically Titanium, Nickel Alloys, Stainless Steel, and Aluminium.

· Proven technical experience in one of the following areas: Chemical Processing, Heat Treatment, Welding, NDT, and Non-Conventional Machining.

· Extensive knowledge of Nadcap requirements with direct experience hosting or supporting Nadcap audits. Strong understanding of AS9100 and AS13100 standards.

· Proven experience interpreting engineering drawings and specifications, alongside deep knowledge of aerospace quality tools (FAIRs, PFMEAs, PPAP and production permits/concessions).

· Experience of managing, coaching, and developing engineering personnel.

· A pragmatic approach to technical problem-solving, balanced with strong commercial awareness and business acumen.

· Competent across standard MS Office packages, with a working knowledge of ERP and QMS systems.

· Exceptional written and verbal communication skills, with the ability to manage external stakeholders (such as auditors and customer technical SMEs) and comfortably interface with health, safety, and environmental standards.